Modular Bulk Material Handling for Dust-Free Glass Batch Houses
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Solution Overview
Problem
Conventional glass batch houses require large, permanent installations that are not relocatable, occupy significant space, and create dusty environments, making them inefficient and costly for smaller-scale or incremental production needs.
Innovation Solution
A modular and mobile bulk material handling system comprising prefabricated modules that include container frames, dispensing modules, and a docking assembly, utilizing dense phase pneumatic conveying to handle bulk materials efficiently and reduce dust exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional glass batch house with permanent installation is used, then bulk material handling capability is provided, but the system occupies large footprint and requires significant construction time
Solution Approach 1:
The system is divided into multiple discrete modules (receiving module, storage module, dispensing module) that can be independently configured and assembled. Each module performs a specific function and can be arranged in different configurations to meet varying production needs, reducing the overall footprint while maintaining handling capability.
Solution Approach 2:
The system employs movable and reconfigurable components including mobile containers on wheeled assemblies, adjustable shelving units, and reconfigurable module arrangements. This dynamic design allows the system to adapt to different space constraints and production requirements without requiring permanent installation.
2Productivity
If a conventional glass batch house with permanent installation is used, then bulk material handling capability is provided, but construction time is significant
Solution Approach 1:
Modules are pre-assembled with integrated components (containers, shelving, conveyors, dust collection) in a controlled manufacturing environment before delivery to the site. This preliminary assembly eliminates on-site construction activities and allows for rapid deployment through simple module placement and connection.
Solution Approach 2:
Traditional mechanical construction methods (welding, bolting, concrete work) are replaced with modular assembly techniques using standardized interfaces and quick-connect mechanisms. The system transitions from a construction project to a assembly operation, dramatically reducing installation time.
3Productivity
If conventional bulk material handling equipment is used, then material transfer is achieved, but dusty environment is created
Solution Approach 1:
Dust collection capabilities are extracted as integrated components of each module rather than as separate external systems. Each module includes its own dust collection device that captures dust at the source of material transfer operations, preventing dust from entering the environment.
Solution Approach 2:
Enclosed conveyors and sealed material transfer pathways act as intermediaries between bulk material storage and dispensing operations. These enclosed systems prevent direct exposure of dust-generating transfer points to the surrounding environment while maintaining efficient material flow.
4Productivity
If conventional glass batch house is used, then complete bulk material handling system is provided, but system complexity and cost increase
Solution Approach 1:
Modules are designed with universal interfaces and standardized configurations that allow the same basic module type to serve multiple functions in different positions within the system. For example, storage modules can be configured for different materials, and dispensing modules can serve different production lines, reducing the variety of unique components needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for rapid capacity expansion and cost-effective, dust-free handling of bulk materials, reducing the need for large footprints and construction time, and enabling efficient operation in smaller-scale or incremental production scenarios.
Implementation Method 1
conveying bulk material directly from a mobile bulk material container into a stationary bulk material container at a glass manufacturing facility via dense phase pneumatic conveying
Data Source
AI summary
A bulk material handling system includes a majors material handling system including bulk material storage modules and bulk material dispensing modules. The dispensing modules include bulk material dosing assemblies and docking assemblies. A bulk material handling method includes conveying bulk material from a mobile bulk material container into a stationary bulk material container at a glass manufacturing facility via dense phase pneumatic conveying.